Zenoah FMZ 1200 Workshop Manual
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Zenoah FMZ 1200 Workshop Manual

Zenoah FMZ 1200 Workshop Manual

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FMZ 1200
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Summary of Contents for Zenoah FMZ 1200

  • Page 1 Workshop manual FMZ 1200 English...

  • Page 2: Table Of Contents

    Table of contents 1 Safety instructions ........... 3 7 Electrical System ..........43 1.1 General directions ............3 7.1 Wiring diagram .............43 1.2 Special directions ............3 7.2 Electrical system components ........44 7.2.1 Microswitch seat ..........44 2 Special tools ............. 4 7.2.2 Microswitch cutting unit ........44 7.2.3 Microswitch pedal carrier ........44 3 Technical data ...........

  • Page 3: Safety Instructions

    Introduction and safety regulations 1 Safety instructions 1.1 General directions During testing, do not touch the muffler before it has This workshop manual is written for personnel with a cooled down. Risk of burns. This is especially true if general knowledge of repairing and servicing Rides. the product is equipped with a catalytic converter.

  • Page 4: Special Tools

    Special tools 2 Special tools The following special tools are used when working on the product. Special tools for engine and transmission can be found in the respective workshop manual. Optical tachometer 502 28 80-01 Puller - belt pulley 506 66 48-01 Tool for measuring wheel 578 92 62-01 Battery charger (EU)

  • Page 5: Technical Data

    Technical data 3 Technical data Dimensions Length without cutting unit, mm/ft 1781/5.84 Length with cutting unit, mm/ft 2100/6.89 Width without cutting unit, mm/ft 797/2.60 Width with cutting unit, mm/ft 883/2.90 Height, mm/ft 1084/3.56 Service weight with cutting unit, kg/lb 191/421 Wheelbase, mm/ft 800/2.62 Tire dimension...
  • Page 6 Technical data Transmission Make Tuff Torq T36P Oil, grade SF-CC SAE 20W/50 Number of forward gears Number of reverse gears Forward speed, km/h Reverse speed, km/h Cutting unit Type Z 85 Cutting heights, 5 positions, mm/inch 25-70 / 1-2 3/4 Blade length, mm/inch 430/17 Note.

  • Page 7: Dealer Service

    Service tools 3.1 Dealer Service 8-hour service 300-hour service 1. Change the engine oil. 1. Inspect the machine. Reach agreement with the customer about which additional work should 25-hour service be carried out. 1. Change engine oil on top valve engine at high 2.

  • Page 8: Service Schedule

    Technical data 3.2 Service Schedule The following is a list of maintenance procedures that must be performed on the product. For those points not described in this workshop manual, refer to the operator’s manual. Page Daily mainte- nance before starting Check the engine oil level Check the engine cooling air intake Check the fuel pump’s air filter...

  • Page 9: Delivery Measures

    Delivery measures 4 Delivery measures 4.1 To our dealers 4.1.1 Packaging and unpacking On delivery from the factory, the product is normally A well-performed delivery service is the first step to a packed in special packing. This comprises a bottom functioning aftermarket.

  • Page 10: Battery

    Delivery measures 4.2 Battery 4.3 Connecting the jump leads WARNING! IMPORTANT INFORMATION Measures after contact with acid Your rider is equipped with a 12-volt system with negative ground. The other vehicle must also have a 12-volt system External: Rinse with plenty of water. with negative ground.

  • Page 11: Steering Wheel

    Delivery measures 4.4 Steering Wheel 4.5 Checking the engine’s oil level Check the engine oil level when the product is standing on a flat surface with the engine turned off. Raise the engine cover. Loosen the dipstick, pull it up and wipe it off. 1 Fit the steering wheel with steering column tube onto the steering column.

  • Page 12: Wheels

    Delivery measures 4.6 Wheels The tire pressure should be 60 kPa (0.6 bar / 8.5 PSI) on all wheels. IMPORTANT INFORMATION Different pressures in the front wheels will make the blades cut the grass at different heights. 12 – English...

  • Page 13: Design And Function

    Design and Function 5 Design and function 5.1 General The product have articulated steering for easy mowing around trees and other obstacles. It also have a front- mounted cutting unit for controlled mowing and the best possible cutting results. The product is also equipped with accessories such as lawn rake and snow blade, making them flexible tools for all-year-round use.

  • Page 14: Serial Numbers

    Design and Function 5.2 Serial numbers The machine’s serial number can be found on the printed plate (1) attached to the right below the engine cover. Stated on the plate, from the left, are: • The machine’s type designation (Model). •...

  • Page 15: Steering

    Design and Function 5.4 Steering The product have articulated steering. The force from the steering wheel is transferred to the rear carriage via cables and a chain. This makes the product easy and precise to steer. The product mows easily around all the obstacles on the lawn.

  • Page 16: Drive

    Design and Function 5.7 Drive 5.8 Cutting unit The product are equipped with hydrostatic The product is equipped with front-mounted cutting transmission that provides the driver with full driving unit to mow efficiently even in confined spaces. control. The speed is controlled variably using the The product have a cutting width of 850 mm (34”).

  • Page 17: Repair Instructions

    Repair instructions 6 Repair instructions 6.1 Dismount the engine 1 First disconnect the negative terminal on the battery and then the positive terminal. IMPORTANT INFORMATION! Hold the bolts so that the poles are not put under strain. 4 Remove the covers on the back of the machine, the side covers and the cover over the fuel tank.
  • Page 18 Repair instructions 5 Place a suitable vessel underneath the fuel tank to collect the gasoline in. 8 Disconnect the engine pin connector, the ground 6 Remove the clamp and hose from the fuel tank cable and the starter motor cable. and drain the fuel into the vessel.
  • Page 19 Repair instructions 11 Unscrew the muffler. 14 Unscrew the remaining 3 screws from the engine block. 12 Unhook the spring on the drive belt pulley in the articulated unit and turn the belt tensioner to one side. 15 Lift off the engine. Assemble in reversed order.

  • Page 20: Fuel Tank

    Repair instructions 6.2 Fuel tank 6.2.1 Removal 6.2.2 Assembly 1 It is easier to work if you empty the tank before WARNING! assembly. Install the tank and secure it with the Gasoline is highly flammable and screws (1). environmentally hazardous. Take great care to prevent fires 2 Put the hose in place and connect it to the fuel and avoid spills.

  • Page 21: Changing Engine Oil

    Repair instructions 6.3 Changing engine oil 6.4 Checking and adjusting the steering cables The steering is controlled with cables. These can The engine oil should be changed the first time after 8 stretch after a time, which means the steering hours running time;...

  • Page 22: Replacing The Steering Cables

    Repair instructions 6.5 Replacing the Steering Cables 4 Ensure that the steering wheel is in the center position when the rear wheels are centered. 1 Loosen the rear fastening of the steering Re-set the chain on the steering column's cables (1). sprocket or adjust the rear fixture (1) for the steering cables as needed.

  • Page 23: Removing/Fitting The Steering Shaft

    Repair instructions 6.6 Removing/Fitting the Steering 4 Unscrew the screw (2) in the lower edge of the steering wheel rod. Shaft 5 Pull the steering wheel shaft (3) upwards and 1 Loosen the rear fastening of the steering move the lower part of the shaft backwards to pull cables (1).

  • Page 24: Removing/Assembling The Cable Pulley

    Repair instructions 6.7 Removing/assembling the cable pulley Ensure that the cables are properly placed in the 1 Loosen the rear fastening of the steering steering cable pulleys (7). cables (1). Ensure that the steering wheel is in the center 2 Remove the screw (2) and the cable pulley (5). position when the rear wheels are centered.

  • Page 25: Checking And Adjusting The Brake Cable

    Repair instructions 6.8 Checking and adjusting the 6.9 Checking and adjusting the brake cable clutch The brake is correctly adjusted when there is no play in the cable. 1 Loosen the lock nuts (1). 1 The clutch is properly adjusted when the idler’s outward motion is stopped by the belt and not by 2 Stretch the cable with the adjustment screw (2) the cable.

  • Page 26: Checking And Adjusting The Accelerator

    Repair instructions 6.11 Changing articulated steering 6.10 Checking and adjusting the bearing accelerator 1 Remove the cover on the right side of the rear carriage. 1 Remove the engine cover by loosening two snap-in locks at the front and two hinges at the back edge of the engine cover.
  • Page 27 Repair instructions 4 Loosen the spring for belt 1 (engine belt) using a spring hook. 7 Loosen the spring that is tensioning belt 2 (transmission belt) using a spring hook. 5 Remove the belt tensioner. 6 Pull belt 1 off the belt pulley. 8 Pull off belt 2 from the transmission, first from the rear belt pulley and then from the front.
  • Page 28 Repair instructions Loosen the two screws (4) using a half-inch 9 Loosen belt 3 (cutting unit drive) from the tension wrench. Loosen the screw (5) behind the muffler roller. Then pull it off from the center belt pulley, and the screw (6) holding the exhaust pipe. The then from the belt pulley of the articulated belt guide can now be removed.Jack up the front steering.

  • Page 29: Removing The Pivoting Rear Axle

    Repair instructions 6.12 Removing the pivoting rear axle 1 Follow step 1 to 15 in "Replacing the Articulated Steering Bearings". 2 Remove the front wheels to obtain better access. 3 Remove all the cables laid out between the front and the rear carriage, in their rear attachments. Make a note of how the cables are laid out.

  • Page 30: Replacing The Pendulum Shaft Bushings

    Repair instructions 6.13 Replacing the pendulum shaft 6.14 Replacing the bearings in the bushings articulation unit belt pulleys Once the swing axle has been remove, the bushings in the rear frame must be changed. Remove the cover (1) on the right hand side. Loosen 1 Remove the articulated shaft with belt pulleys, the spring (2) with a spring hook.

  • Page 31: Assembling The Pivoting Rear Axle

    Repair instructions 6.15 Assembling the pivoting rear axle 5 Fit the articulated shaft with the short key grip 1 Slide the washer (2) on the pendulum shaft with and plastic cover face down. Ensure the double the beveled edge against the fork (1) of the D shaft is inserted into the double D hole on the pendulum shaft.

  • Page 32: Replacing The Hydrostatic Cable

    Repair instructions 6.16 Replacing the hydrostatic cable 6.16.1 Removing the hydrostatic cable 3 Remove the front hydrostatic cable clamp that is fastened inside the center console. 4 Cut off the plastic tie around the cable at the 1 Remove the frame cover and the front cover. frame situated in front of the left front wheel.
  • Page 33 Repair instructions Fitting the hydrostatic cable 6 Lift the link joint off and remove the hydrostatic 1 Feed the new cable through the product so it runs cable. Loosen the rear link joint from the cable. the same route as the old one. Turn the cable so that it comes loose from the front link joint.
  • Page 34 Repair instructions 4 Tighten the hydrostatic transmission cable clamp. 7 Place the hydrostatic transmission cable in place and screw the casing on with the rear bracket (3). 8 Adjust the hydrostatic transmission cable as shown, see Checking and Adjusting the Accelerator.

  • Page 35: Replacing Brake Cable

    Repair instructions 6.17 Replacing brake cable 6.17.1 Removing the brake cable 6.17.2 Fitting the brake cable 1 Pull through the new brake cable on the product. 1 Unhook the spring in the front part of the brake cable. 2 Fit the rear of the cable. 3 Fit the front part of the cable by hooking on the 2 Loosen the rear part and remove the brake cable spring.

  • Page 36: Replacing Belt 4, As Far As The Cutting Unit

    Repair instructions 6.18 Replacing belt 4, as far as the cutting unit Starting position for removing belts: • No unit is attached to the machine. • The front part of the belt is loose. • The lifting lever is lowered. 1 Jack up the front carriage and remove the left front wheel.

  • Page 37: Replacing Belt 3, Cutting Unit Drive

    Repair instructions 6.19 Replacing belt 3, cutting unit drive Follow the instructions for "Replacing belt 4, as far as the cutting unit" up until step 7. Then proceed according to the following instructions: 7 Pull belt 3 off the unit belt pulley. 1 Remove the rear cover of the front frame.
  • Page 38 Repair instructions 6 Remove the cover on the left hand side of the rear carriage. 4 Lift off belt 1. 5 Remove the spring for the belt tensioner for belt 2 (transmission belt). 7 Pull off belt 2 from the transmission, first from the rear belt pulley and then from the front.

  • Page 39: Removing The Cutting Unit

    Repair instructions 6.20 Removing the cutting unit The cutting unit can be removed in order to facilitate cleaning and servicing. To remove the cutting unit proceed as follows: 1 Put the machine in a level position. 5 Loosen the snap-in lock and lift off front cover. 2 Apply and secure the parking brake.

  • Page 40: Service Position For Cutting Unit

    Repair instructions 6.21 Service position for cutting unit Follow the instructions for "Removing the cutting unit" above. Lift off the unit and lean it against the machine or a wall. 4 Push the unit until you feel the pipes touch bottom.

  • Page 41: Removal Of Blades And Blade Housing

    Repair instructions 6.22 Removal of blades and blade housing WARNING! Use gloves and protective goggles when working on the cutting unit. The cutting unit should be removed from the machine, see "Removing the cutting unit". 4 Secure the blade with a wooden block or hold the belt pulley with an oil filter puller for example.

  • Page 42: Grinding And Balancing Blades

    Repair instructions 7 The whole bearing package is available as a complete kit with shaft housing, shaft and bearings. Assembly is done in reverse order to dismantling. 3 Balance the blades as follows: The blade bolt tightening torque is 45-50 Nm (32-36 lb ft).

  • Page 43: Electrical System

    Electrical system 7 Electrical System 7.1 Wiring diagram 1. Microswitch, seat 6. Starter relay 2. Ignition switch 7. Grounding point engine 3. Microswitch, lifting lever 8. Starter motor 4. Microswitch, pedal 9. Solenoid valve carburettor 5. Fuse, 15A 10. Battery English –...

  • Page 44: Electrical System Components

    Electrical system 7.2 Electrical system components 7.2.2 Microswitch cutting unit The electrical system consists of four cables, three microswitches, one ignition switch and one fuse. If the product does not start (the start engine does not rotate when the key switch is turned to the starting position), one of the electrical system components might be damaged.

  • Page 45: Ignition And Starter Switch

    Electrical system 7.3 Ignition and starter switch 7.4 Main fuse The main fuse is placed in a detachable holder 1 Unplug the connector from the ignition switch by behind the battery under the protective cover. pulling straight down. 2 Remove the ignition key and the rubber seal. 3 Remove the nut and the ignition switch.
  • Page 46 46 – English...
  • Page 47 115 98 26-26 English – 47...

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